Advantages of Aluminum in Future Automotive and New Energy Vehicles

  • Release time: 2026-01-26

With the development of automobiles towards lightweighting and the significant increase in the use of new energy vehicles, the usage of aluminum in new energy vehicles has grown at a rate of around 30% annually! The "range requirement" has greatly increased the usage of aluminum in new energy vehicles. By 2025, the annual growth rate of domestic aluminum rolled plates and extruded materials will reach around 30%! All major automobile manufacturers are targeting materials such as aluminum used in new energy vehicles. 
Metal new material experts believe that automotive lightweighting is the key to reducing the fuel consumption of traditional energy vehicles and increasing the range of new energy vehicles. For new energy vehicles, aluminum is the lightweight material that will replace steel structures. The lightweighting of automotive development and the adoption of aluminum rolled plates, extruded materials, and integrated die-cast alloys in new energy vehicles are beneficial to the leading companies in the niche market. 
Aluminum used in new energy vehicles is one of the lightweight materials for automobiles. According to Chen Jiarui's statistics in "Automobile Structure", the vehicle weight can be reduced by 10%, and the fuel efficiency can be increased by 6% to 8%. Aluminum is one of the lightweight materials. The "Energy Saving and New Energy Vehicle Technology Roadmap" proposes the target for aluminum usage in lightweight bicycles in China: 250 kg per vehicle in 2025 and 350 kg per vehicle in 2030. 

 

According to the data from the International Aluminum Association, in 2020, the amount of aluminum used for traditional passenger vehicles in China was approximately 138.6 kg per vehicle. For pure electric and hybrid new energy passenger vehicles, the aluminum consumption was 157.9 kg and 198.1 kg respectively. Additionally, according to Ducker Frontier's data, in 2020, the aluminum consumption per vehicle in North America for non-pure electric vehicles was 206 kg, and for pure electric vehicles, it was 292 kg. There is still a significant room for improvement in the penetration rate of aluminum materials in domestic automobiles. 
Lightweighting and new energy vehicles make greater use of rolled sheets, extruded materials, and integrated die-cast materials. The aluminum used in new energy vehicles mainly consists of four types: rolled sheets, extruded materials, cast aluminum alloys, and forged materials. The emergence of new energy vehicles, due to the requirement for range, has significantly expanded the usage space for rolled and extruded materials. Currently, the usage of aluminum and extruded materials in new energy vehicles in China is four times that of traditional energy vehicles. Therefore, the growth rate of aluminum rolled and extruded materials for vehicles is much higher than that of aluminum materials for vehicles. There are mainly two logical reasons for this: 
① The consumption of this type of aluminum material for new energy vehicles is significantly higher than that for traditional energy vehicles. As a result, with the rapid increase in the penetration rate of new energy vehicles, the consumption volume has also increased significantly. 
② The current base is low and the penetration rate is not high. There is considerable room for significant improvement in the context of lightweighting. 
Furthermore, the integrated die-casting process, which has gradually been adopted by large automobile manufacturers, can be regarded as the beginning of the integration of automotive components. The main application components are concentrated on the rear floor of the vehicle. The original 70+ parts have been consolidated into 1-2 parts, significantly reducing the number of molds and presses, and rapidly increasing production efficiency, as well as bringing about a substantial reduction in costs. It is estimated that the aluminum usage in a single die-casting process is approximately 100kg. The promotion of this process will greatly increase the penetration rate of aluminum in automobiles.

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